Method of manufacturing a semiconductor device

ABSTRACT

Embodiments relate to a method of manufacturing a semiconductor device that may simplify a manufacturing process and may reduce process costs. According to embodiments, the method may include simultaneously forming a first gate of a first device area and a second gate of a second device area, patterning a PMD layer to form a first contact hole exposing the first gate, depositing and planarizing a high dielectric constant material and first and second metallic materials on the semiconductor substrate to expose PMD layer, forming an insulating layer, a metal layer and a third gate in the first contact hole, patterning the PMD layer to form a second contact hole exposing the second gate, and depositing a third metallic material on the semiconductor substrate and planarizing it such that the PMD layer is exposed, thereby forming a contact in the second contact hole.

The present application claims priority under 35 U.S.C. 119 and 35 U.S.C. 365 to Korean Patent Application No. 10-2005-0133397 (filed on Dec. 29, 2005), which is hereby incorporated by reference in its entirety.

BACKGROUND

Semiconductor devices may be divided into various categories, including memory devices and non-memory devices. In memory devices, information may be stored, and in non-memory devices, information may not be stored.

Memory devices may be generally divided into volatile memory devices, in which recorded information may be erased and new information may be stored, and non-volatile memory devices, in which information recorded once may be permanently stored.

Volatile memory devices may include RAM (Random Access Memory), which may allow information to be written and read. Non-volatile memory may include ROM (Read Only Memory), EPROM (Erasable Programmable ROM), and EEPROM (Electrically Erasable Programmable ROM), which may allow information to be read.

Memory and non-memory devices may be simultaneously designed in accordance with a various known layouts on a semiconductor substrate.

FIG. 1 is an example sectional diagram showing a semiconductor device having memory and non-memory devices.

Referring to FIG. 1, memory and non-memory devices 1 and 2 may be formed on a semiconductor substrate 3.

Memory device 1 may include gate insulating layer 6 a, floating gate 7, interlayer dielectric layer 8, and control gate 9. These elements may be stacked. Source and drain areas 4 a and 4 b may be formed at both side areas of control gate 9.

Interlayer dielectric layer 8 may be an ONO (Oxide-Nitride-Oxide) layer. Floating gate 7 may be an area in which information is written. Gate insulating layer 6 a may be formed to isolate semiconductor substrate 3 and floating gate 7. Control gate 9 may be formed to control floating gate 7, for example to write or delete information. Interlayer dielectric layer 8 may be formed to isolate floating gate 7 and control gate 9.

Spacer 10 a may be formed at sides of gate insulating layer 6 a, floating gate 7, interlayer dielectric layer 8 and control gate 9.

In non-memory device 2, gate insulating layer 6 b and general gate 9 a may be stacked. Source and drain areas 5 a and 5 b may be formed at both side areas of general gate 9 a. General gate 9 a may conduct and cut off a channel area between source and drain areas 5 a and 5 b such that signals may be transmitted therebetween.

Further, gate insulating layer 6 b may be formed to isolate semiconductor substrate 3 and general gate 9 a. Spacer 10 b may be formed at sides of gate insulating layer 6 b and general gate 9 a.

PMD (Pre-Metallic Dielectric) layer 12 may be formed on semiconductor substrate 3. PMD layer 12 may include contact holes for electrical connections to general gate 9 a, control gate 9, source areas 4 a and 5 a, and drain areas 4 b and 5 b. Metal interconnection 13 may be formed through each of the contact holes, and tungsten (W) 11 may be filled in the contact hole.

Control gate 9 may include a material substantially identical to a material forming general gate 9 a.

Therefore, control gate 9 and general gate 9 a may be formed through a one-time mask process in a semiconductor process.

However, since a step difference may exist between control gate 9 and general gate 9 a, focuses for exposure may be different from each other when performing an exposure process, for example to form a photoresist pattern. For this reason, it may not be possible to simultaneously form control gate 9 and general gate 9 a through a one-time mask process.

For example, since control gate 9 may be formed on floating gate 7 and interlayer dielectric layer 8, control gate 9 may be positioned higher than general gate 9 a by a height of floating gate 7 and interlayer dielectric layer 8.

Accordingly, a step difference may be formed as high as floating gate 7 and interlayer dielectric layer 8 between control gate 9 and general gate 9 a.

Thus, if a focus for exposure is adjusted on a photoresist on interlayer dielectric layer 8 to deposit the photoresist on semiconductor substrate 3 including interlayer dielectric layer 8 and then expose the photoresist, the focus may not be properly adjusted on the photoresist in an area in which general gate 9 a will be formed.

If an exposure is then performed, an exact photoresist pattern may be formed on interlayer dielectric layer 8, while the precise photoresist pattern may not formed on an area in which general gate 9 a will be formed.

Thus, since a general gate having an inexact CD (Critical Dimension) may be formed where patterning is performed using an inexact photoresist as a mask, an inexact operation may be accomplished by such a general gate.

Therefore, it may be necessary for a control gate and a general gate, which may have the same material, to be formed through a two-time mask process and not through a one-time mask process. Such a process may be complicated, expensive, and time consuming.

SUMMARY

Embodiments relate to a semiconductor device. Embodiments relate to a method of manufacturing a semiconductor device that may simplify a process and reduce process costs.

Embodiments relate to a method of manufacturing a semiconductor device, in which a general gate of a non-memory device and a floating gate of a memory device may be simultaneously formed so that a process may be simplified and process costs can be reduced.

Embodiments relate to a method of manufacturing a semiconductor device, in which a control gate may include a metallic material so that the performance of the control gate may be enhanced.

According to embodiments, a method of manufacturing a semiconductor device in which first and second areas may be defined on a semiconductor substrate, and first and second devices may respectively be formed in the first and second areas, may include simultaneously forming a first gate of the first device area and a second gate of the second device area, depositing a PMD layer on the semiconductor substrate and then patterning it, thereby forming a first contact hole such that the first gate may be exposed, depositing a high dielectric constant material and first and second metallic materials on the semiconductor substrate and then planarizing them such that the PMD layer may be exposed, thereby forming an insulating layer, a metal layer and a third gate in the first contact hole, patterning the PMD layer, thereby forming a second contact hole such that the second gate may be exposed, and depositing a third metallic material on the semiconductor substrate and then planarizing it such that the PMD layer may be exposed, thereby forming a contact in the second contact hole.

According to embodiments, a method of manufacturing a semiconductor device in which first and second areas may be defined on a semiconductor substrate, and first and second devices may be respectively formed in the first and second areas, may include simultaneously forming a first gate of the first device area and a second gate of the second device area, depositing a first PMD layer on the semiconductor substrate and then patterning it, thereby forming a first contact hole such that the first gate may be exposed, depositing a high dielectric constant material and first and second metallic materials on the semiconductor substrate and then planarizing them such that the first PMD layer may be exposed, thereby forming an insulating layer, a metal layer and a third gate in the first contact hole, depositing a second PMD layer on the semiconductor substrate and then patterning it, thereby forming a second contact hole such that second and third gates may be exposed, and depositing a third metallic material on the semiconductor substrate and then planarizing it such that the second PMD layer may be exposed, thereby forming a contact in the second contact hole.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is an example sectional diagram illustrating a semiconductor device having memory and non-memory devices;

FIGS. 2 a to 2 i are example sectional diagrams illustrating a semiconductor and a process of manufacturing a semiconductor according to embodiments; and

FIGS. 3 a to 3 h are example sectional diagrams illustrating a semiconductor and a process of manufacturing a semiconductor according to embodiments.

DETAILED DESCRIPTION OF EMBODIMENTS

Referring to FIG. 2 a, semiconductor substrate 21 may include areas in which memory and non-memory devices will be formed. A plurality of memory and non-memory devices may be formed on semiconductor substrate 21.

Memory devices, non-memory devices, and memory and non-memory devices may be isolated by a field oxide layer (not shown). Thus, a region of each of the devices may be defined by the field oxide layer.

General gate (as distinguished from floating and control gates) 23 b and first source and drain regions 26 a and 26 b may be formed in a non-memory device area on semiconductor substrate 21. Further, floating gate 23 a and second source and drain areas 25 a and 25 b may be formed in the memory device area.

First gate oxide layer 22 b may be formed between general gate 23 b and semiconductor substrate 21. First gate, oxide layer 22 b may provide isolation between general gate 23 b in substrate 21. Second oxide layer 22 a may be formed between the floating gate 23 a and semiconductor substrate 21, and may provide isolation therebetween.

First spacers 24 b may be formed at both side surfaces of first gate oxide layer 22 b and general gate 23 b, and second spacers 24 a may be formed at both side surfaces of second gate oxide layer 22 a and the floating gate 23 a.

General gate 23 b may include a material substantially identical to a material used to form floating gate 23 a. General gate 23 b and floating gate 23 a may be simultaneously formed through a one-time mask process.

In embodiments, a gate oxide layer and a poly-silicon layer may be deposited on the semiconductor substrate, and a photoresist may be coated on the poly-silicon. A photoresist pattern may then be formed, for example through an exposure and development process. A patterning process may then be performed, for example using the photoresist pattern as a mask. General gate 23 b and floating gate 23 a may thereby respectively be formed in the non-memory and memory device areas.

First source and drain areas 26 a and 26 b of the non-memory device may be formed through an ion implantation process, for example by using general gate 23 b and first spacers 24 b as a mask.

Second source and drain regions 25 a and 25 b of the memory device may be formed through an ion implantation process, for example by using floating gate 23 a and second spacers 24 a as a mask.

Referring to FIG. 2 b, a PMD layer 27 may be deposited on semiconductor substrate 21 having general gate 23 b and floating gate 23 a.

Referring to FIG. 2 c, first contact hole 28 may be formed by patterning PMD layer 27 such that floating gate 23 a and second spacers 24 a of the memory device may be exposed. According to embodiments, first contact hole 28 may be formed through an RIE process.

Referring to FIG. 2 d, high dielectric constant (high k) material (e.g., Al₂O₃ or the like) 29 and barrier metal (e.g., Ti, TiN or the like) 30 may be sequentially deposited on semiconductor substrate 21.

Referring to FIG. 2 e, metallic material 31′ such as tungsten (W) may be deposited on barrier metal 30.

Referring to FIG. 2 f, metallic material 31′ may be planarized, for example through a CMP process. PMD layer 27 may thus be exposed. Accordingly, metallic material 31′ may be formed only in first contact hole 28, and control gate 31 may be formed by metallic material 31′ formed in first contact hole 28.

High dielectric constant material 29 and barrier metal 30 may be stacked on side and bottom surfaces of first contact hole 28. Control gate 31 may be formed on barrier metal 30. High dielectric constant material 29 may induce higher capacitance so that more information may be recorded. Barrier metal 30 may be formed, and may increase the adhesion of control gate 31.

In general, a control gate may include poly-silicon. According to embodiments, control gate 31 may include a metallic material such as tungsten. Current loss may thereby be minimized since a resistance of the metallic material may be lower than that of the poly-silicon. In embodiments, exact operational control may be possible and a performance of control gate 31 may be enhanced.

Referring to FIG. 2 g, PMD layer 27 may be patterned through an RIE process, and second contact holes 33 and 34 may thus be formed. First source and drain areas 26 a and 26 b and general gate 23 b of the non-memory device are may be respectively exposed through second contact holes 33 and 34. Third contact holes 32 may also be formed, through which second source and drain areas 25 a and 25 b may be respectively exposed.

Referring to FIG. 2 h, a metallic material such as tungsten may be deposited on PMD layer 27 having the second and third contact holes 32, 33 and 34, and then planarized, for example through a CMP process. PMD layer 27 may thus be exposed, thereby forming contacts 36 in the second and third contact holes 32, 33 and 34. Contact 36 may include a metallic material (e.g., tungsten) identical to or different from a material forming barrier metal 30.

Referring to FIG. 2 i, a metallic material such as Al or Cu may be deposited on PMD layer 27 and may be patterned, thereby forming metal interconnections 38 on contacts 36.

According to embodiments, a plurality of memory and non-memory devices 35 and 37 may be simultaneously formed on semiconductor substrate 21.

According to embodiments, general gate 23 b of non-memory device 37 and floating gate 23 a of memory device 35 may be simultaneously formed. Hence, a manufacturing process may be simplified, and costs may be reduced.

In addition, according to embodiments, control gate 31 may include a metallic material, which may increase conductivity, for example as compared with related art techniques. Hence, and exact operation may be controlled.

FIGS. 3 a to 3 h are example sectional diagrams illustrating a semiconductor and a process of manufacturing a semiconductor according to embodiments.

FIGS. 3 a to 3 f illustrate the same components as to FIGS. 2 a to 2 f, and will accordingly be only briefly described for convenience of explanation.

Referring to FIG. 3 a, general gate 23 b and first source and drain areas 26 a and 26 b may be formed in a non-memory device area of semiconductor substrate 21. Floating gate 23 a and second source and drain areas 25 a and 25 b may be formed in a memory device area of semiconductor substrate 21. First and second gate insulating layers 22 a and 22 b may be formed between respective gates 23 a and 23 b and semiconductor substrate 21, and first and second spacers 24 a and 24 b may be formed on side surfaces of respective gates 23 a and 23 b.

Referring to FIG. 3 b, first PMD film 27 may be deposited on semiconductor substrate 21. Referring to FIG. 3 c, first contact hole 28 may be formed, for example through an RIE process such that floating gate 23 a and second spacer 24 a in the memory device area may be exposed.

Referring to FIG. 3 b, high dielectric constant material 29 such as Al₂O₃ and barrier metal 30 such as Ti or TiN may be sequentially deposited.

Referring to FIG. 3 e, metallic material 31′ such as tungsten may be deposited on barrier metal 30 and planarized through a CMP process.

Referring to FIG. 3 f, control gate 31 in first contact hole 28 may thus be formed.

Referring to FIG. 3 g, after forming control gate 31, second PMD layer 41 may be deposited on semiconductor substrate 21. Second contact holes 43 may be formed such that respective gates 23 b and 31, first and second source areas 25 a and 26 a, and first and second drain areas 25 b and 26 b may be exposed. Thus second contact holes 43 may be formed in the non-memory device area such that general gate 23 b and first source and drain areas 26 a and 26 b may be exposed, and second contact holes 43 may be formed in the memory device area such that floating gate 23 a and second source and drain areas 25 a and 25 b may be exposed.

Second PMD film 41 may include a dielectric material identical to or different from a material used to form first PMD film 27.

Referring to FIG. 3 h, a metallic material such as tungsten may be deposited on semiconductor substrate 21 and planarized, for example through a CMP process. Contacts 45 may thus be formed in contact holes 43. A metallic material such as Al or Cu may be deposited on contacts 45 and then patterned. Metal interconnections may thus be formed on contacts 45. Contacts 45 may include a metallic material (e.g., tungsten) identical to barrier metal 30 or a metallic material different therefrom.

Accordingly, a plurality of memory and non-memory devices 50 and 55 may be simultaneously formed on semiconductor substrate 21.

According to embodiments, general gate 23 b of the non-memory device 55 and floating gate 23 a of the memory device 50 may be simultaneously formed, and a manufacturing process may thus be less complicated and less expensive.

Further, according to embodiments, control gate 31 may include a metallic material, which may increase conductivity, for example as compared to related are techniques. An exact operation may therefore be controlled.

Furthermore, in embodiments, second PMD layer 41 may be added. Hence, control gate 31 may not exposed directly to the outside, and an occurrence of a short circuit due to metal interconnections intersecting each other may be prevented.

According to embodiments, a general gate of a non-memory device and a floating gate of a memory device may be simultaneously formed, and a process can be simplified and process costs may be reduced.

According to embodiments, a control gate 31 may include a metallic material, and may have a high conductivity. Hence, an operation may be better controlled.

According to embodiments, a second PMD layer may also be formed. A control gate may not be exposed directly to the outside. A short circuit due to metal interconnections intersecting each other may be therefore be prevented.

According to embodiments, an interlayer dielectric layer may include a high dielectric constant material such as Al₂O₃ rather than an existing ONO layer. Accordingly, a process may be simplified and costs may be reduced. For example, since an ONO layer may be prepared as three layers, three-time deposition, one-time exposure, RIR, and wet etching processes may be added, and may cause a process to be very complicated. On the contrary, according to embodiments, an interlayer dielectric layer may simply include a high dielectric constant material such as Al₂O₃, and a process may be simplified and costs may be reduced.

It will be apparent to those skilled in the art that various modifications and variations can be made to embodiments. Thus, it is intended that embodiments cover modifications and variations thereof within the scope of the appended claims. It is also understood that when a layer is referred to as being “on” or “over” another layer or substrate, it can be directly on the other layer or substrate, or intervening layers may also be present. 

1. A method comprising: simultaneously forming a first gate over a first device area and a second gate over a second device area of a semiconductor substrate; depositing a PMD layer on the semiconductor substrate and patterning the PMD layer to form a first contact hole exposing only the first gate; and forming an insulating layer, a metal layer, and a third gate in the first contact hole over the first gate, the third gate being a control gate.
 2. The method of claim 1, wherein forming the insulating layer, the metal layer, and the third gate comprises depositing a high dielectric constant material and first and second metallic materials over the semiconductor substrate and planarizing them to expose the PMD layer.
 3. The method of claim 2, wherein the high dielectric constant material comprises Al₂O₃.
 4. The method of claim 1, further comprising: patterning the PMD layer to form a second contact hole exposing the second gate; and depositing a third metallic material over the semiconductor substrate and planarizing it such that the PMD layer is exposed, to form a contact in the second contact hole.
 5. The method of claim 4, further comprising forming a second PMD layer over the first device area and the second device area, forming second contact holes in the second PMD layer over the second gate and third gate, and forming contacts within the second contact holes electrically connected to the second gate and third gate, respectively.
 6. The method of claim 4, wherein the third gate comprises a metallic material substantially identical to a metallic material forming the contact.
 7. The method of claim 4, wherein the third gate comprises a metallic material different from a material forming the contact.
 8. The method of claim 1, wherein the insulating layer provides capacitance.
 9. The method of claim 1, wherein the metal layer is configured to attach the third gate to the insulating layer.
 10. The method of claim 1, wherein the first metallic material comprises Ti or TiN.
 11. The method of claim 1, wherein the second metallic material comprises W.
 12. A method comprising: simultaneously forming a first gate of a first device area and a second gate of a second device area over a semiconductor substrate; depositing a first PMD layer on the semiconductor substrate and patterning it to form a first contact hole exposing the first gate; forming an insulating layer, a metal layer, and a third gate in the first contact hole by depositing a high dielectric constant material and first and second metallic materials over the semiconductor substrate and planarizing them to expose the first PMD layer; forming second contact holes by depositing a second PMD layer on the semiconductor substrate and patterning the second PMD layer to expose the second and third gates; and forming contacts in the second contact holes by depositing a third metallic material on the semiconductor substrate and planarizing it to expose the second PMD layer.
 13. The method of claim 12, wherein the insulating layer forms capacitance.
 14. The method of claim 12, wherein the high dielectric constant material comprises Al₂O₃.
 15. The method of claim 12, wherein the metal layer is configured to couple the third gate to the insulating layer.
 16. The method of claim 12, wherein the first metallic material comprises Ti or TiN.
 17. (canceled)
 18. The method of claim 12, wherein the third gate comprises a metallic material identical to a metallic material forming the contact.
 19. The method of claim 12, wherein the third gate comprises a metallic material different from a material forming the contact.
 20. The method of claim 12, wherein the first PMD layer comprises an insulating material identical to a material forming the second PMD layer.
 21. The method of claim 12, wherein the first PMD layer comprises an insulating material different from a material forming the second PMD layer. 